An apparatus for removing magnetic particles from a mud slurry is disclosed, and includes one or more endless belts or chains enclosed almost wholly within a pipe. A motor drives the chain around the pipe. When the pipe is located within a mud slurry, magnetic particles in the mud slurry are drawn to the pipe and carried along the outside and away from the slurry until a collar is reached. Once separated the particles can be collected for disposal. The chain comprises a series of units linked together. Each unit includes a magnet with pole pieces at either pole to direct magnetic flux. wear discs prevent the magnets and pole pieces from abrasion as they are drawn through the pipe. Units can be included in the chain which units do not include a magnet, thereby providing a break in the field, allowing particles to fall away from the collar region.
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1. An apparatus for removing magnetic particles from liquid or slurry, said apparatus comprising:
a support frame;
a plurality of endless chains, each endless chain including along a length of the endless chain a plurality of magnetic field generation units to attract magnetic particles;
a plurality of pipes arranged in an array and connected to the support frame along a width of the support frame, each pipe providing an enclosing means associated with and surrounding a single one of the plurality of endless chains, for preventing contact of magnetic particles with said plurality of magnetic field generation units;
drive means to circulate each of the plurality of endless chains within a respective pipe of the plurality of pipes; and
collection means to collect the magnetic particles,
wherein the drive means is configured to circulate each endless chain to pass through a bore defined by its associated pipe by drawing the endless chain along the pipe, and wherein the bore of a pipe defines a path followed by its associated endless chain;
wherein each plurality of magnetic field generation units is configured to direct a magnetic flux out of its associated pipe around the entirety of an outside surface of the pipe to attract magnetic particles to the outside surface of the pipe;
wherein each endless chain draws the magnetic particles along the outside surface of its associated pipe to the collection means; and
wherein each endless chain comprises, from the plurality of magnetic field generation units, a group of adjacent magnetic field generation units linked together, and comprises at least one non-magnetic unit positioned between two magnetic field generation units in the endless chain.
28. An apparatus for removing magnetic particles from liquid or slurry;
said apparatus comprising:
a support frame;
a plurality of endless chains, each endless chain including along a length of the endless chain a plurality of magnetic field generation units to attract magnetic particles;
a plurality of pipes arranged in an array and connected to the support frame along a width of the support frame, each pipe providing an enclosing means associated with and surrounding a single one of the plurality of endless chains, for preventing contact of magnetic particles with said plurality of magnetic field generation units;
drive means to circulate each of the plurality of endless chains within a respective enclosing means; and
collection means to collect the magnetic particles;
wherein the drive means is configured to circulate each endless chain to pass through a bore defined by its associated pipe by drawing the endless chain along the pipe, and wherein each of the pipes follows a curved path;
wherein each plurality of magnetic field generation units is configured to direct magnetic flux out of its associated pipe all around the surface of the pipe to attract magnetic particles to the outside of the pipe;
wherein each endless chain draws the magnetic particles along the outside of its associated pipe to the collection means;
wherein each of the plurality of magnetic field generation units includes a pair of wear discs, a first wear disc of the pair of wear discs being positioned at a first end of the magnetic field generation unit and a second wear disc of the pair of wear discs being positioned at a second end of the magnetic field generation unit;
wherein the drive means comprises a drive wheel associated with each pipe, and wherein each drive wheel comprises teeth which engage the wear discs of the magnetic field generation units of the endless chain associated with the pipe to draw the endless chain around the pipe.
18. An apparatus for removing magnetic particles from a fluid-carrying channel of a flowing fluid, the apparatus comprising:
a support frame;
a plurality of endless chains, each endless chain including along a length of the endless chain a plurality of magnetic field generation units to attract magnetic particles;
a plurality of pipes connected to the support frame along a width of the support frame, each pipe providing an enclosing means associated with and surrounding a single one of the plurality of endless chains for preventing contact of magnetic particles with the magnetic field generation units;
a drive means to circulate each of the plurality of endless chains within a respective pipe;
and a collection means to collect the magnetic particles;
wherein the plurality of enclosing means are arranged in an array configured to be located on a fluid-carrying channel;
wherein the drive means is configured to circulate each of the plurality of endless chains to pass through a bore defined by each endless chain's associated pipe by drawing the endless chain along the pipe, and wherein the bore of a pipe defines a path followed by its associated endless chain;
wherein each of the plurality of magnetic field generation units is configured to direct magnetic flux out of its associated pipe all around an outside surface of the pipe to attract magnetic particles to the outside surface of the pipe;
wherein each of the plurality of endless chains draws the magnetic particles along the outside surface of its associated pipe to the collection means;
wherein the array is spaced to enable fluid to pass between adjacent pipes, and is arranged to enable the width of the channel to be subjected to magnetic fields generated by the plurality of magnetic field generation units; and
wherein each endless chain comprises, from the plurality of magnetic field generation units, a group of adjacent magnetic field generation units linked together, and comprises at least one non-magnetic unit positioned between two magnetic field generation units in the endless chain.
25. An apparatus for removing magnetic particles from liquid or slurry;
said apparatus comprising:
a support frame;
a plurality of endless chains, each endless chain including along a length of the endless chain a plurality of magnetic field generation units to attract magnetic particles;
a plurality of pipes arranged in an array and connected to the support frame along a width of the support frame, each pipe providing an enclosing means associated with and surrounding a single one of the plurality of endless chains, for preventing contact of magnetic particles with said plurality of magnetic field generation units;
drive means to circulate each of the plurality of endless chains within a respective enclosing means; and
collection means to collect the magnetic particles;
wherein the drive means is configured to circulate each endless chain to pass through a bore defined by its associated pipe by drawing the endless chain along the pipe, and wherein each of the pipes follows a curved path;
wherein each plurality of magnetic field generation units is configured to direct magnetic flux out of its associated pipe all around the surface of the pipe to attract magnetic particles to the outside of the pipe;
wherein each endless chain draws the magnetic particles along the outside of its associated pipe to the collection means;
wherein each of the plurality of magnetic field generation units includes a pair of wear discs, a first wear disc of the pair of wear discs being positioned at a first end of the magnetic field generation unit and a second wear disc of the pair of wear discs being positioned at a second end of the magnetic field generation unit, and wherein each wear disc has a diameter greater than a diameter of a permanent magnet of the magnetic field generation unit; and
wherein the wear discs of the magnetic field generation units of each endless chain contact an inner wall of the bore of a respective pipe, such that the bore of the pipe defines a path followed by its associated endless chain, and guides the associated endless chain around the pipe.
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16. A system for removing magnetic particles from a flowing fluid, the system comprising:
an apparatus as claimed in
a device, separated from the apparatus in a flow direction, the device comprising an elongate magnetic field generator; a casing separating said generator from the liquid or slurry;
wherein the magnetic field generated by the elongate magnetic field generator passes through the casing of the device, causing magnetic particles in the liquid or slurry to be attracted to said device and be retained on said casing; and
wherein the device further comprises means for removing the attracted particles from the field generated by said elongate magnetic field generator, enabling the particles to be removed from said device.
17. An apparatus according to
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wherein the wear discs of the magnetic field generation units of each endless chain contact an inner wall of the bore of a respective pipe, such that the bore of the pipe defines a path followed by its associated endless chain and guides the associated endless chain around the pipe.
30. An apparatus according to
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This application is a continuation of U.S. application Ser. No. 11/990,870, filed Mar. 20, 2009, entitled “REMOVAL OF MAGNETIC PARTICLES FROM A FLUID”, now abandoned, which is a National Stage Application of International Application No. PCT/GB2006/003148 filed Aug. 22, 2006, which claims the benefit of United Kingdom Patent Application No. 0517252.3, filed Aug. 24, 2005 and United Kingdom Patent Application No. 0614493.5, filed Jul. 21, 2006, all of which are incorporated herein by reference.
1. The Field of the Invention
The present invention relates to apparatus for removing magnetic particles from a fluid. The apparatus finds particular application in the oil and gas industry in relation to separating iron-containing swarf from free-flowing or viscous liquid mud.
2. The Relevant Technology
Oil and gas wells usually have their bore holes lined with steel pipes, referred to normally as casing. In mature wells, when oil or gas production drops below economic production levels, it is often useful to utilise at least part of said bore hole. In order to be able to do this one alternative is to remove the casing completely. However, it is more cost effective to simply drill the pipeline out, or at least to drill a window in the pipeline. The window can then be used to allow a drilling assembly to exit the bore hole and reach a new part of the reservoir.
Such a method obviously produces large quantities of steel swarf derived primarily from the pipeline. The swarf is mixed during the drilling process with large quantities of mud either from the bore hole or from its introduction as a lubricant. Typically the mud/swarf mixture will comprise a sufficient quantity of water to enable the mixture to flow. Due to the high steel content of the mud when it exits the bore hole and its potential hazard, in part due to the sharpness of the metal slithers it contains, disposal or re-use of the mud can be problematic. One method of decontamination is simply to remove excess water from the mixture and then separate the larger swarf pieces by hand. This is obviously a time consuming and potentially dangerous mode of separation.
It is an object of the present invention to provide an improved apparatus to separate the solid magnetic or magnatisable particles from a fluid system and in particular, apparatus which can be applied in the oil and gas industry.
According to a first aspect of the invention there is provided an apparatus for removing magnetic particles from a liquid or slurry; the apparatus comprising;
(a) an endless belt or chain, including along its length, a plurality of magnetic field generation units to attract magnetic particles;
(b) an enclosing means preventing contact of magnetic particles with the magnetic field generators;
(c) drive means to circulate the endless belt within the enclosing means;
(d) collection means to collect the particles.
The apparatus provides a simple and efficient method to separate the magnetic particles from the slurry allowing the magnetic particles to be disposed of more easily or to be reused.
Preferably, one or more magnetic field generation units comprises one or more permanent magnets, which do not therefore require an electricity supply to function. The units further preferably comprise one or more pole pieces to direct the magnetic field of the magnets. Optionally the units include one or more wear discs to reduce wear on the magnets or pole pieces. Advantageously, the or each magnet includes a hole along its axis to enable linkage means to be attached to the unit.
Preferably the endless belt or chain consists of a plurality of units linked together. Particularly preferably the chain includes one or more units not including a magnet. The gap in the magnetic field resulting in the lack of magnet allows swarf to be more easily removed from the apparatus.
The apparatus preferably includes one or more enclosing means arranged in an array each enclosing means associated with an endless belt. By combining a plurality of enclosing means a larger flow of mud can be subjected to swarf removal.
The relative positions of enclosing means can optionally be adjusted, thereby allowing channels of different shapes to be used to allow mud flow. Advantageously, the or each enclosing means is mounted to mounting means. Further advantageously, the enclosing means is formed of steel.
According to a second aspect of the invention there is provided a device for removing magnetic particles from a liquid or slurry, the device comprising;
(a) an elongate magnetic field generator;
(b) a casing separating the generator from a liquid or slurry;
(c) the magnetic field passing through the casing causing magnetic particles to be attracted to the device and be retained on the casing;
(d) means for removing the attracted particles from the field generated by the generator, enabling the particles to be removed from the device.
Preferably, the device comprises a helical cleaning means, rotatable about the axis of the magnetic field generator, the inner surface of the cleaning means engaging the casing and rotation of the cleaning means moving the attracted particles from the field generated by the generator.
Alternatively, the device preferably includes a cleaning barrier, engaging the casing around the generator, the barrier being moveable between a first and second position, the motion pushing the particles out of the field generated by the generator. The particulars can thereby easily be removed from the device.
Advantageously, the magnetic generator comprises a stack of magnets alternating polarity along the length of the generator.
Optionally, the magnetic poles are orientated along the length of the axis of the field generator. The magnetic field generated levels to push away from the device which is of assistance when moving particles. Alternatively, the poles are orientated perpendicularly to the axis of the field generator. The magnetic field assists motion of the particles along the axis of the device.
According to a third aspect of the invention there is provided an array for removing magnetic particles from a liquid or slurry, the device comprising;
(a) one or more magnets, said the or each magnet being housed within a casing;
(b) the housing being attached to a framework, which framework being locatable on a fluid-carrying channel, and such that the or each casing is at least partially immersed in the fluid.
The invention will now be described with respect to the accompanying drawings which show by way of example only, embodiments of swarf removing apparatus. In the drawings;
Referring initially to
In the first section, the mud is passed around a series of steel pipes 11 of an apparatus 10 through which pipes 11 an endless chain of magnets, moving in the opposite direction to the flow of the mud, is circulated. In the second section, the mud passes a series of static magnets 13 the magnets 13 remove any swarf not caught in the first section.
The apparatus 10 is shown in more detail in
In
The above arrangement allows the apparatus to be used in mud channels of differing cross-sectional shape. This is illustrated in
It will be obvious to the skilled man, that through this means, channels of different cross-sectional shape to the above exemplified can be dealt with by the apparatus.
Turning to the magnetic chain, this is shown in more detail in
The basic magnetic unit comprises a substantially cylindrical magnetic element or magnet 50 formed of a transition metal magnet having a cylindrical hole along its axis. Pole pieces 51a, 51b are affixed to the end of the magnet 50. The pole pieces 51a, 51b are formed of soft iron and act to direct magnetic flux out of the pipe to facilitate attraction of swarf in the mud flow. Wear discs 52a, 52b which are resistant to wear are secured to each pole piece 51a, 51b. As can be seen from the Figures, the diameter of the wear discs 52a, 52b greater than that of the magnet 50 and the pole pieces 51 to ensure that the wear discs 52a, 52b wear away sacrificially. The elements 50, 51 and 52 can be quickly removed and replaced with a similar unit when necessary.
In order to enable the magnets to be secured to one another, the unit is provided at a first end with a female clevis 57 and at a second end with a corresponding male clevis 58. To ensure that the basic unit remains together, a stud 53 is fixed across the assembly passing through the holes in the magnet 50, pole pieces 51a, 51b and wear discs 52a, 52b. A screw or bolt is passed through the holes 54, 55 in each clevis 57, 58 and through the stud 53.
In order to link adjacent magnets therefore, the clevis of each neighbouring magnetic unit is aligned, with opposite poles adjacent to each other, and secured to one another, allowing the units to pivot relative to one another. Sufficient units are linked together eventually to form an endless chain which passes through and is enclosed almost completely, by the steel pipe.
In use it has been found that care needs to be taken to provide breaks in the magnetic field, to allow the swarf to be released from the pipe, to enable the outside of the pipe 22 around the region of the collar 24 to be kept free of swarf. One solution to this problem is to replace the magnet in alternate links with a dummy, non-magnetic element 56. As the chain moves through the pipe therefore, the region around the collar 24 is periodically subject to magnetic fields which are not strong enough to retain the swarf, allowing the swarf to drop into the collection chute 25. It will be apparent that the weakening of the field can be achieved in a number of ways. For example, in similar fashion to the embodiment described above, every third, fourth etc magnet can be excluded. Alternatively or additionally, the distance between magnets can be increased.
Although it has been found advantageous to include gaps in the field it is not essential, and the amount of swarf in the collar region can be allowed to build up until its own weight causes a proportion of the mass built up to fall into the chute.
A drive mechanism for the chain including the magnet units of
In use therefore, the supporting frame is located above the channel through which the mud contained in the swarf is to flow. The drive mechanism and the steel pipes through which the magnetic chains are drawn, are located on the support frame such that the base of the steel pipes guiding the chain are close to the bottom of the channel and spaced apart sufficient that the space between the pipes is small enough for the entire width of the mud in the channel to be subjected to a magnetic field. If necessary, a pipe can be tilted to enable the pipe layout to conform to the shape of the channel. Moreover, the pipes are aligned such that the movement of the chain within the pipe is opposed to the flow of the mud in the section of pipe below the mud surface.
The drive meal's is then activated, circulating the magnetic chain within the pipe. The mud is allowed to flow within the channel. As the mud flows past the pipes, metal swarf is attracted to the pipe and, due to the chain circulation, is carried out of the mud along the outside of the pipe until it engages the collar 24. As a magnetic element 50 of the chain together with the swarf particles attracted by that element 50 circulates beyond the collar 24, the magnetic field retaining the swarf particles drops and the swarf particles fall from the pipe into a collection chute. Using the above apparatus, and a typical swarf-containing mud, approximately 800-1000 gallons of mud have been processed at a rate of yield of 1 ton/hour of swarf.
The second section of the apparatus shown in
The rod 70 further includes a swarf stop 75 in the form of an annulus mounted about the outside of the case 71 and at the height of the top of the magnet 72, when the magnet 72 is in its lower position. A support 76 enables the rod 70 to be held in position in the channel by a suitable frame.
In use therefore, the rod or series of rods 70 is positioned in the channel. The magnet 72 is lowered within the case 71 by operation of the swarf-rod 73. The flow of mud within the channel is commenced and as the mud flows around the rod 70, swarf in the mud is attracted to the case 71 and held there by the magnet 72. When sufficient swarf has been collected, the rod 70 is lifted out of the mud stream. The handle 74 is used to pull the magnet 72 from one end of the case 71 to the other. As this occurs, the accumulated swarf is pulled along the case until it reaches the stop 75. Eventually, as all of the magnet 72 is withdrawn above the level of the stop 75, the swarf drops off, preferably into a suitable collection vessel.
A further embodiment of the rods shown in
As will be envisaged therefore any swarf attracted to the magnets in the shaft 101 will be pushed by the helix 102 up the shaft 101 towards the motor 103. Eventually as the swarf reaches the upper half of the shaft 101, the magnetic attraction exerted by the magnets in the shaft 101 on the swarf reduces eventually until the force is insufficient to retain the swarf and it falls from the rod 100. The rod 100 is orientated at around 45° to the horizontal to ensure that when the swarf is released from the rod it does not fall back down the rod 100, but instead falls into a collection element (not illustrated).
In
In use therefore, swarf removed from the mud flow by the rods 110 is conveyed by the helices 102 up the shaft 101 of the rod 110. The swarf is eventually conveyed into the non-magnetic region of the rods 110. Here the swarf is attracted to the magnetic region of the rod 104. From here, the swarf is conveyed along the rod 104 by the helix 102 in the direction of the motor 105. Swarf is conveyed to the nonmagnetic region of the rod 104 from which it falls under gravity and can be collected in a suitable container.
In a further embodiment of the invention, as shown in
In an alternative embodiment, not illustrated, the swarf can be removed from the steel pipe by a brush means. Such a brush means is particularly suited for use where the magnetic field generated by the magnetic chain is fairly continuous, and at least sufficient to hold the swarf against the pipe in the region of the collar.
It will be appreciated that the embodiment of
It will of course be understood that the invention is not limited to the specific details described herein, which are given by way of example only, and that various modifications and alterations are possible with the scope of the appended claims.
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